Selectively activated electrochemical cell system

ABSTRACT

A power generating system is described including a plurality of electrochemical cells. The cells are generally arranged in sections that are selectively activated individually or in combination to produce power from selected cell sections. A method of generating power is also described. A first group of one or more electrochemical cells of an array of cells are selectively activated based on requirement of an associated load. The system switches to a second group of one or more electrochemical cells of the array when the first group is discharged.

RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.10/045,896, filed Oct. 19, 2001, now U.S. Pat. No. 6,713,988, whichclaims the benefit of U.S. Provisional Application Ser. No. 60/306,769entitled “Selectively Activated Electrochemical Cell System” filed onJul. 20, 2001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a selectively activated electrochemicalcell system, and more particularly to such a system wherein individualcells or groups of cells may be activated in various successionsdepending on energy and power requirements.

2. Description of the Prior Art

A variety of systems use electrochemical cells such as batteries andfuel cells to meet power needs. For example, many portable devices,backup systems, vehicles, and other power consuming systems useelectrochemical cells

A key requirement for an electrochemical cell system is to meet thepower requirements. Another concern relates to the energy of the cell,which is the length of time that the required power may be provided tothe load. Heretofore, it has been extremely difficult to combine highpower and high energy

A further problem associated with electrochemical cell systems,particularly primary batteries, is that once a battery is activated, itremains active until it is discharged by utilization of the usefulenergy in the battery, self discharge, corrosion, or combinationsthereof. Therefore, interruptibility of conventional batteries, in manycircumstances, is limited.

It would be desirable to provide a system that can produce high powerand high energy, while further allowing for interruptibility, andtherefore extending the useful lifetime of the system.

SUMMARY OF THE INVENTION

The above-discussed and other problems and deficiencies of the prior artare overcome or alleviated by the several methods and apparatus of thepresent invention, wherein a power generating system is describedincluding a plurality of electrochemical cells. The cells are generallyarranged in sections that are selectively activated individually or incombination to produce power from selected cell sections. A method ofgenerating power is also described. A first group of one or moreelectrochemical cells of an array of cells are selectively activatedbased on requirement of an associated load. The system switches to asecond group of one or more electrochemical cells of the array when thefirst group is discharged.

The above-discussed and other features and advantages of the presentinvention will be appreciated and understood by those skilled in the artfrom the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C is a schematic depiction of one embodiment of a selectivelyactivated electrochemical cell system in operation;

FIG. 2A is a schematic depiction of another embodiment of a selectivelyactivated electrochemical cell system having activation switches open;

FIG. 2B depicts the system of FIG. 2A in a mode of operation utilizing asection of a first type of cells;

FIG. 2C depicts the system of FIG. 2A in a mode of operation utilizing asection of a second type of cells;

FIG. 2D depicts the system of FIG. 2A in a mode of operation utilizingsections of both a first type and a second type of cells;

FIG. 2E depicts the system of FIG. 2A in a mode of operation showing onesection of a first type of cells partially discharged and furtherutilizing another section of a first type of cells;

FIG. 2F depicts the system of FIG. 2A in a mode of operation showing onesection of a first type of cells discharged and further utilizinganother section of a first type of cells;

FIGS. 2G & 2H graphically depict the condition and associatedoperational variations of the a selectively activated electrochemicalcell system and the system's response to a simulated load;

FIG. 3 is a schematic depiction of a selectively activatedelectrochemical cell system and associated subsystems;

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring now to FIGS. 1A-1C, a selectively activated electrochemicalcell system 100 is schematically depicted in operation. The system 100is selectively coupled to an electrical load 130. The system 100comprises a plurality of electrochemical cells 110-113 arranged in apair of strings (cells 110 and 111 in series, and cells 112 and 113 inseries). A controller 140 is provided to selectively activate one ormore of the strings. Note that the controller 140 may comprise acomputer operably coupled to switches associated with each cell or agroup of cells, a manually operated control coupled to switchesassociated with each cell or a group of cells (which are switched by auser as needed), or a combination thereof.

The type of battery may be primary or secondary (i.e., rechargeable), ora combination of primary and secondary batteries. The cells 110-113 maybe the same or different. Types of batteries include, but are notlimited to, alkaline, lead-acid, nickel cadmium, metal air, lithiumpolymer, nickel metal hydride, nickel zinc, magnesium zinc, anycombination comprising at least one of the foregoing, and the like. Oneor more of the cells may also be fuel cells, such as hydrogen based fuelcells such as proton exchange membrane fuel cells or solid oxide fuelcells, metal air fuel cells, any combination comprising at least one ofthe foregoing, and the like.

During operation, the power demands of load 130 are met by one or bothstrings of cells 110, 111 or cells 112, 113. The number of the stringsselected is controlled by the controller 140. For example, if the powerrequirement for the load 130 is 100 W, and each of the cells 110-113 arecapable of producing 50 W, the controller 140 may activate only thestring of cells 110, 111 to power the load 130. If the power demandcontinues beyond the capacity of the selected cell string, thecontroller 140 may deactivate the cell string 110, 111 and activateanother fresh cell string (e.g., cells 112, 113).

By individually activating strings of cells, particularly in primarybattery systems, the limitations related to lack of interruptability areovercome. That is, by using one string of cells to power the load 130,the remaining string (or strings, as the system may provide) are leftwith the full power and capacity, and discharging of such remainingcells is not initiated, even if the energy is provided from the stringof cells 110, 111 to the load 130 is insufficient to discharge suchstring. Accordingly, if the system is interrupted, only cells 110, 111will be subject to detriments associated with discharge interruption(e.g., self discharge), unlike conventional battery systems that are notdiscrete and separately activatable.

In another example, if the load 130 requires 200 W for operation, thecontroller 140 may activate both the string of cells 110, 111 and thestring of cells 112, 113. As shown in FIGS. 1A-1C, the strings are inparallel, however, it is understood that they may be in series, orswitchable between series and parallel, depending on the loadrequirements.

In a further example, if the load 130 initially requires 100 W foroperation, the controller 140 will activate the string of cells 110,111. If the demand subsequently rises to 200 W, the controller 140 willactivate the string of cells 112, 113 to power the load 130. Byappropriate control, the depth of discharge and the energy utilized fromeach cell can be maximized.

When one or more of the cells 110-113, or cell strings 110, 111 and 112,113, are discharged, they may be replaced (individually or in strings)by the user (e.g., manually) or with an automated system. The one ormore cells are preferably replaced without interruption of the poweroutput of the system (that is, if the load 130 is in continuing demandfor power from the system 100).

Referring particularly to FIG. 1A, both cell strings 110, 111 and 112,113 are inactive (note the switches are open and the cells are notshaded). To commence power to the load 130, where the single string ofcells 110, 111 is sufficient, the string of cells 110, 111 is activated,as shown in FIG. 1B (wherein the associated switch is closed, and cells110, 111 are shaded). In the event that additional power is required, orif cells 110, 111 are drained (e.g., below a predetermined voltagelevel), the string of cells 112, 113 may be activated, as shown in FIG.1C (wherein the switch for cells 110, 111 may remain closed, or beopened (as indicated by dashed lines), and wherein drained cells areindicated with diagonal stripes). Note that the cells 110, 111 mayremain in parallel to drain any remaining power therefrom.

The controller 140 may be a computer that is operably coupled toswitches to selectively activate one or more of the strings of cells110, 111 or 112, 113. The controller 140 may monitor the needs of theload 130 to selectively activate one or more of the strings of cells110, 111 or 112, 113. Alternatively, the system 100 including acomputer-based controller 140 may be manually operated. The controller140 can monitor the load requirement, such that a determination is madeas to how many of the strings of cells 110, 111 or 112, 113 to activate,and in what configuration (i.e., parallel, series, or a combinationthereof), if applicable. Switching between the cells may be based on atimer, such that once activation commences, the controller 140 willswitch to another cell after a certain period of time. The time may be aconstant for the particular cell or type of cell, or may vary based onmonitoring of the load 130. Alternatively, the switching may be based onthe status of the selectively activated string(s), which can bemonitored by the controller 140. The status may be monitored by varioussub-systems, including but not limited to: monitoring the real-timepower output of the selectively activated cell(s), wherein the cell(s)will be switched when the remaining calculated energy or the voltagedrops below a preselected level; or monitoring the chemicalcharacteristics the cell(s) (e.g., by monitoring the expansion of thecell, which (in metal air cells) may be related to the chemicalproperties since the metal is converted to a higher volume metal oxidematerial; or by monitoring the composition of the electrolyte).

The controller 140 may also provide other features, including, but notlimited to: monitoring the status of the cells including non-activecells (individually or in groups), monitoring the temperature of thesystem 100; providing cooling when needed (wherein a cooling sub-systemis also provided in the system 100); automatically ejecting structurescontaining one or more of the cells when discharged to facilitatereplacement thereof (wherein an ejection sub-system is also provided inthe system 100); providing safety features, such as indicators,self-deactivation, and self-extinguishing (e.g., in the event of fire,wherein an extinguishing sub-system is also provided in the system 100);or any combination comprising at least one of the foregoing. The poweroutput of the system 100 may also be conditioned or converted, forexample, from DC to AC, or from DC to DC (at different voltages), as isknown in the power supply art. The system and/or loads may also beprotected with one or more circuit breakers or fuses.

Power for the controller 140 and any included sub-systems may be derivedfrom one of the cells in the system 100. Where a rechargeable cell isprovided, it is preferred to power the controller with said rechargeablecell. Alternatively, a suitable capacity rechargeable cell can beprovided that is dedicated to the controller.

In another embodiment, a system may be provided wherein each cell isactivated by incorporation of electrolyte in the cell. When electrolyteis added from a separate source, such as a bladder, syringe, tank, etc.,the cell is activated. Thus, virtually infinite shelf life may beattained for the inactivated cells. For example, a system maintainingelectrolyte out of contact with active cell components is described inU.S. Provisional Application Ser. No. 60/309,730 entitled “ReserveBattery” filed on Aug. 2, 2001 by Nicholas Pasquale.

Referring now to FIGS. 2A-2H, another embodiment of a selectivelyactivated electrochemical cell system and various modes of operationthereof are depicted. A selectively activated electrochemical cellsystem 200 includes a plurality of cell strings 210, 212, 214, 216 and218. Note that any number of strings, or cells within each string, maybe incorporated in the system, depending on the particular needs.

In the system 200, string 218 is a string of relatively high powerproducing cells with relatively low energy capacity (as compared tostrings 210, 212, 214 and 216), and strings 210, 212, 214 and 216 arestrings of relatively high energy capacity cells with relatively lowpower output (as compared to string 218). For example, string 218 maycomprise a string of secondary batteries (e.g., rechargeable lead-acidor nickel cadmium), and the strings 210, 212, 214 and 216 may compriseprimary batteries (e.g., alkaline cells or metal air cells). Thissystem, a hybrid system, is particularly useful for meeting demands ofload 230 when the power requirement increases, as in a spike, induction,inrush, start-up, or other transient load characteristic.

For example, consider an environment wherein the system 200 is utilizedas a backup power system, and that the load 230 typically operates atless than 100 W, and occasionally increases to 300 W. Further, considerthe example where string 218 comprises a high power (300 W), low energy(50 W-H) lead-acid battery, and strings 210, 212, 214 and 216 comprisehigh energy (500 W-H), low power (100 W) zinc-air batteries, that may bereplaced or refueled (e.g., by replacing the zinc in the batteries).String 218 is intended to handle up to 300 W peaks of the load 230.Strings 210, 212, 214 and 216 may be used for lower power requirements.In one example, string 218 may be connected to the load 230 via a diodethat only becomes forward biased when the current demand of the load 230is sufficient to cause a voltage drop within one of the selected strings210, 212, 214 and 216 corresponding to a 100 W load (e.g., the maximumof each of each of strings 210, 212, 214 and 216). Further, for lowpower uses, the string 218 may handle the load 230 for the first fewminutes of operation of system 200, or when it is known that the system200 will be operational for only a few minutes. In this manner, one ormore of the strings 210, 212, 214 and 216 are not activated until string218 is discharged. With certain types of cells, once a cell isactivated, it will remain active until it is discharged either byextracting the useful energy or by self-discharge. Therefore, byactivating only certain strings, the power reserve (i.e., within theinactivated strings) remains intact.

In the mode of operation depicted in FIG. 2B, the switch associated withstring 210 is closed, thus string 210 is providing power to load 230. Asdiscussed above, this situation is intended for load demands below themaximum power of the string 210. Further, use of the string 210 ispreferably for a time period sufficient to utilize capacity with thestring 210, so as to minimize wasted power (particularly wherein thenature of the cells within the string 210 are such that self dischargeis a concern).

In the mode of operation depicted in FIG. 2C, the switch associated withstring 218 is closed, thus string 218 is providing power to load 230. Asdiscussed above, this situation is intended for load demands above themaximum power capabilities of the string 210. The string 218 ispreferably activated below a time period that would otherwise completelydrain the cells therein. Thus, in various preferred embodiments, thecontrol approximates the upcoming needs of the system 200, and causesutilization of string 218 for, e.g., transients or short term needs.

In the mode of operation depicted in FIG. 2D, the switches associatedwith string 218 and string 210 are closed. In one embodiment, dependingon associated control (not shown), string 218 may provide power to load230, whereas string 210 provides recharging current for string 218. Inanother embodiment, string 210 may provide power to both meet the needsof load 230 and recharge string 218. In still a further embodiment,strings 210 and 218, in parallel, may provide power for the load 230,e.g., during a high current transient condition.

In the mode of operation depicted in FIG. 2E, the switches associatedwith strings 210 and 212 are closed. In this embodiment, as depicted bythe shading variations in the Figure, string 210 has been in operationfor some time when string 212 is initiated. For instance, this may beuseful when the current demand for the load 230 increases to a higherlevel for a period of time, and the capacity of the string 218 isinsufficient. Further, this mode may be useful to compensate for anyvoltage drop in the string 210 after a period of operation.

In the mode of operation depicted in FIG. 2F, the switch associated withstring 212 is closed. In this embodiment, as depicted by the diagonallines in the cells of string 210, string 210 is discharged orsubstantially discharged. Note that the switch associated with string210 may be closed or open (as indicated with dashed lines). In certaincircumstances, it may be desirable to maintain connection with string210, for example, to withdraw any remaining power from the cells.

Graphical simulated operational analysis of a hybrid system similar tothat depicted in FIG. 2A is provided in FIGS. 2G and 2H. In particular,the system is simulated based on a section of zinc-air batteries(Zn-air) and a section of lead acid (Pb—Ac) batteries. The section ofZn-air cells is characterized as two parallel strings of ten cells. Eachcell has an open circuit voltage of 1.44 V, an internal resistance of 75milliohms, a capacity of 15 W*h, and a depth of discharge of 50%. ThePb—Ac section is characterized by six Bolder Technologies 95 Sub C(Golden, Colo.) cells in series each having an open voltage of 2.00 V,4.4 milliohms internal resistance, an energy capacity of 0.862 A*h percell at 50 A, and a recharge efficiency of 55%. The Pb—Ac sectionengages at about 8 amperes of current draw, generally to supply thedifference between the upper load demand and the Zn-air power output.The simulation is based on a theoretical, but quite plausible loadingprofile.

As shown in FIG. 2G, as the load current increases, the Zn-air sectionis unable to meet the demands, causing a voltage drop. To compensate,the Pb—Ac supplies additional power. As shown, this occurs when the loadis about 8 amperes, corresponding to 11.4 volts. At this level, a diodeassociated with the Pb—Ac section becomes forward biased.

Referring to FIG. 2H, a simulated 120 second load condition is depicted.Note that while the load current is low (e.g., lower than about 5 A),the load is powered by the Zn-air section. However, as the load spikesto about 30 A, the draw on the Zn-air section increases (to a maximum of9.4 A), while the draw on the Pb—Ac section increases from 0 A to over20 A. As the load current decreases, the draw from the Pb—Ac section ishalted, and accordingly, the Zn-air section powers the load. Further,the Zn-air section provides recharging power to the Pb—Ac section. Asimilar effect is shown with the load current spike to about 15 A. Notethat the recharging allows the Pb—Ac section to be completely rechargedat the end of the 120 second cycle.

Referring now to FIG. 3, a selectively activated electrochemical cellsystem 300 is depicted, including associated subsystems which may bepresent in a hybrid system for enhanced control and capability. Thesystem 300 includes primary electrochemical cell sections 310 (cells 310₁, 310 ₂, 310 ₃, 310 ₄ . . . 310 _(N)), 312 (cells 312 ₁, 312 ₂, 312 ₃,312 ₄ . . . 312 _(N)), and 314 (cells 314 ₁, 314 ₂, 314 ₃, 314 ₄ . . .314 _(N)), wherein the sections are in parallel; and a secondaryelectrochemical cell section 318 (cells 318 ₁, 318 ₂, 318 ₃, 318 ₄ . . .318 _(N)), which is in parallel with the primary cell sections 310, 312and 314.

In general, the cell sections are controlled with a controller 340,which performs various functions and interacts with associatedsubsystems. For user interaction with the system 300, a user panel 342is provided, including user control and status display. Sectionalactivation is provided with a power switch drive signal for controllingthe switches associated with the sections. The AC line, e.g., which thesystem 300 backs up, is monitored by the controller 340. Current andvoltage sensing systems are also provided, for example, to provide datafor use by the controller 340. In systems where each cell undergoes amechanical or electronic activation (i.e., as opposed to sectionalactivation), an actuation/triggering control signal may be provided.Also, in certain types of cell systems, temperature sensing is alsoprovided, for example, whereby the controller 340 provides signals tooptional fans 354 (as indicated by dashed lines) Note that while severaltypes are displayed in FIG. 3, it will be apparent to those skilled inthe art that certain functions are not required in certain types ofcells or necessary systems, and further that additional functions mayalso be provided.

To provide for a hybrid system 300, wherein the secondary section 318undertakes power provision during certain circumstances, a diode 346 isprovided. The diode 346 only becomes forward biased when the currentdemand of the load is sufficient to cause a voltage drop within one ofthe selected strings 310, 312 and 314. With a sufficiently intelligentcontroller 340 combined with sufficient sensing elements the diode 346can be eliminated (as well as its associated power losses) since theswitch in series with string 318 can be controlled in a manor thatreplaces the function of the diode 346.

The system 300 further includes various associated subsystems. Powersupplies 344 are included for providing suitable power for controller340, and any included drivers, transducers, actuators, etc. A maincharger 348 is also included, which provides suitable power conditioning(e.g., DC to DC) to allow charging of the secondary cell section 318(e.g., a Pb-acid system) from the primary cell sections 310, 312 and 314(e.g., Zn-air). Also, an optional DC-AC inverter 350 (indicated bydashed lines) may be provided, for example, to invert power from theelectrochemical cell system 300 to a AC load or load system. Further, anoptional accessory charger 352 is provided (indicated by dashed lines),e.g., which inverts an AC line to suitable DC power for charging thesecondary cell section 318. Of course, plural optional circuit breakers356 (indicated by dashed lines) may also be included, generally toprotect the system circuitry and any connected loads.

The selectively activated electrochemical cell system provides manybenefits in various applications. For example, emergency power systemsmay endure very long periods of non-operation without substantiallydiminishing power or capacity, even after they have been operated.Electric vehicles may be able to provide the necessary power for shortterm boosts, for example, with a rechargeable cell, while operatingunder “normal” conditions with a plurality of selectively activatedprimary cells, thereby facilitating long trips without manual refuelingof the cells or recharging. Uninterruptible power supplies may include,for example, several arrays of typical primary or secondary batteries,such as “AA” size batteries. When one array is consumed, the controllerswitches to another array, whereby the user may replace the consumedarray without power interruption.

While preferred embodiments have been shown and described, variousmodifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustrations and not limitation.

1. A power generating system comprising: a plurality of electrochemicalcells that are selectively activated individually or in combination toproduce power from selected cells, wherein the plurality of cellsincludes a plurality of strings of primary cells and at least onerechargeable cell, wherein upon activation of one of said plurality ofstrings of primary cells, said activated string of cells is draineduntil an output voltage of said activated string of cells is below apredetermined voltage level prior to switching to another of saidplurality of strings of primary cells.
 2. The power generating system asin claim 1, further comprising a controller to selectively activate oneor more cells.
 3. An electrochemical power system for connection to aload comprising: a plurality of arrays of primary electrochemical cellsin a parallel configuration, each array including a plurality ofelectrochemical cells arranged in series; and a controller system forcontrolling which one or more arrays of the plurality of arrays is to bein connection with the load upon demand of the load, wherein uponactivation of one of said plurality of arrays of primary electrochemicalcells, said activated arrays of primary electrochemical cells is draineduntil an output voltage of said activated string of cells is below apredetermined voltage level required by the load prior to switching toanother of said plurality of strings of primary electrochemical cells.4. The system as in claim 3, the controller system includes a switchassociated with each of the arrays and a logic system.
 5. Anelectrochemical cell system comprising: a plurality of sections ofprimary electrochemical cells, wherein individual sections arecontrolled for activation of one section or for activation insuccessions, wherein upon activation of one of said plurality ofsections of primary electrochemical cells, said activated sections ofprimary electrochemical cells is drained until an output voltage of saidactivated section of cells is below a predetermined voltage level priorto switching to another of said plurality of sections of primaryelectrochemical cells.
 6. The electrochemical cell system as in claim 5,wherein at least one section comprises metal air electrochemical cells.7. The electrochemical cell system as in claim 6, further wherein atleast one section comprises secondary electrochemical cells.
 8. Theelectrochemical cell system as in claim 7, wherein the secondaryelectrochemical cells have a higher power output and lower capacity thanthe metal air electrochemical cells, and further wherein activationcontrol provided for activation of the metal air electrochemical cellsat a load below a predetermined level value or range and activation ofthe secondary electrochemical cells at a load above a predeterminedlevel value or range.
 9. The electrochemical cell system as in claim 7,wherein upon activation of section of metal air electrochemical cells inresponse to a load current, the activated section discharges to apreselected depth of discharge or until completely discharged.
 10. Theelectrochemical cell system as in claim 6, wherein the metal airelectrochemical cells comprise reserve cells wherein cell componentsselected from the group of electrolyte, oxidant, anode, cathode, and anycombination comprising at least one of the foregoing components areincorporated into the cells upon activation or at a controlled timeprior to activation.
 11. A method of generating power comprising:selectively activating a first group of one or more groups of primaryelectrochemical cells of an array of such groups of cells based onrequirement of an associated load, wherein the at least one group isallows to self discharge after connection with a load if the load demandhalts; and switching to a second group of one or more electrochemicalcells of the array when the first group is discharged, or removing theconnection to the load if the load demand halts.
 12. The method as inclaim 11, further comprising switching to a third group of one or moreelectrochemical cells of the array when the second group is discharged.13. The method as in claim 11, wherein the first group comprisesrechargeable cells and the second group comprises primary cells.